Pilz PSEN enc sincos/HTL User manual

PSEN enc sincos/HTL
Operating Manual-1005022-EN-01
}PSEN sensor technology

Preface
This document is the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for the user's internal purposes. Suggestions and comments for improving this documenta-
tion will be gratefully received.
Source code from third-party manufacturers or open source software has been used for
some components. The relevant licence information is available on the Internet on the Pilz
homepage.
Pilz®, PIT®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, SafetyBUS p®,
SafetyEYE®, SafetyNET p®, the spirit of safety® are registered and protected trademarks
of Pilz GmbH & Co. KG in some countries.
SD means Secure Digital

Contents
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Contents
Contents.................................................................................................................. 2
1 General information ............................................................................................ 4
1.1 Applicability............................................................................................................................. 4
1.2 Abbreviations and terms used................................................................................................ 5
1.3 General functional description................................................................................................ 6
1.3.1 Main features .......................................................................................................... 7
1.3.1.1 PSEN enc sincos 4096 hs, PSEN enc sincos 4096 ss ............................. 7
1.3.1.2 PSEN enc HTL 1024 ss, PSEN enc HTL 1024 hs.................................... 7
1.3.2 Principle of the safety function................................................................................ 7
2 Basic safety information..................................................................................... 8
2.1 Definition of symbols and notes.............................................................................................. 8
2.2 General risks when using the product .................................................................................... 9
2.3 Intended use........................................................................................................................... 10
2.4 Non-intended use ................................................................................................................... 10
2.5 Safety functions of the fail-safe evaluation device.................................................................. 11
2.5.1 Mandatory safety checks / measures ..................................................................... 11
2.6 Warranty and liability .............................................................................................................. 12
2.7 Organizational measures........................................................................................................ 12
2.8 Personnel selection and qualification; basic obligations ........................................................ 12
2.9 Safety information................................................................................................................... 13
3 Transport / Storage ............................................................................................. 15
4 Technical data...................................................................................................... 16
4.1 Safety...................................................................................................................................... 16
4.2 Electrical characteristics......................................................................................................... 17
4.2.1 General ................................................................................................................... 17
4.2.2 Device-specific........................................................................................................ 17
4.3 Ambient conditions ................................................................................................................. 18
4.4 Mechanical characteristics...................................................................................................... 19
4.4.1 Solid shaft ............................................................................................................... 19
4.4.2 Hollow shaft............................................................................................................. 19
5 Mounting .............................................................................................................. 20
5.1 Solid shaft............................................................................................................................... 20
5.1.1 Requirements.......................................................................................................... 20
5.2 Hollow shaft ............................................................................................................................ 22
5.2.1 Requirements.......................................................................................................... 22
6 Installation / Preparation for Commissioning ................................................... 24

Contents
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6.1 EMC requirements.................................................................................................................. 25
6.2 EMC conform wiring schemes................................................................................................ 26
6.2.1 Connection scheme 1 ............................................................................................. 26
6.2.2 Connection scheme 2 ............................................................................................. 26
6.2.3 Connection scheme 3 ............................................................................................. 27
6.3 Ground connection –measuring system................................................................................ 28
6.5 Cable specification.................................................................................................................. 29
6.6 Permitted cable length............................................................................................................ 30
6.7 Pin assignment ....................................................................................................................... 30
6.7.1 PSEN enc SIN/COS................................................................................................ 30
6.7.2 PSEN enc HTL........................................................................................................ 31
6.8 Connection to evaluation device............................................................................................. 32
6.8.1 Evaluation device PNOZ s30.................................................................................. 32
6.8.2 Evaluation device PNOZ m EF 1/2MM................................................................... 32
6.8.3 Evaluation device PSSu K F EI (CV)...................................................................... 32
7 Incremental interface........................................................................................... 33
7.1 Analogue incremental signals (SIN/COS) .............................................................................. 34
7.2 Square-wave incremental signals (HTL) ................................................................................ 35
8 Checklist............................................................................................................... 36
9
Bestelldaten............................................................................................................ Fe
hler! Textmarke nicht definiert.
9.1 Measuring System.................................................................................................................. 37
9.2 Accessories............................................................................................................................. 37
10 EC declaration of conformity............................................................................ 38

General information
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1 General information
This operating manual contains the following topics:
●General functional description
●Basic safety information with declaration of the intended use
●Characteristics
●Mounting
●Installation/Commissioning
●Error causes and remedies
This document is intended for instruction. Only install and commission the product if you
have read and understood this document. The document should be retained for future
reference.
1.1 Applicability
This documentation is valid for the products:
●PSEN enc sincos 4096 hs
●PSEN enc sincos 4096 ss
●PSEN enc HTL 1024 ss
●PSEN enc HTL 1024 hs
It is valid until new documentation is published.

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1.2 Abbreviations and terms used
DCavg
Diagnostic Coverage
Average diagnostic coverage
ESD
Electro Static Discharge
EU
European Union
EMC
ElectroMagnetic Compatibility
Functional
safety
(FS)
Part of the overall system safety, which depends on the correct functioning of safety-
related systems for risk reduction. Functional safety is ensured when each safety
function is executed as specified.
Fault
exclusion
Compromise between the technical safety requirements and the theoretical possibility of
an error occurring
HTL
High-Threshold-Logic
IEC
International Electrotechnical Commission
IEEE
Institute of Electrical and Electronics Engineers
ISO
International Standard Organization
MTTFd
Mean Time ToFailure (dangerous)
Mean time until dangerous failure
PFDav
Average Probability of Failure on Demand
Average probability of failure of a safety function with low demand
PFH
Probability of Failure per Hour
Operating mode with high requirement rate or continuous demand. Probability of
dangerous failure per hour.
PFHD
Probability of a dangerous Failure per Hour
Average probability of a dangerous failure per hour according to ISO 13849-1.
PL
Performance Level, according to ISO 13849-1: Discrete level, which specifies the
capability of safety-related parts of a control to execute a safety function under
foreseeable conditions.
SIL
Safety Integrity Level, according to IEC 62061: Four discrete levels (SIL1 to SIL4). The
higher the SIL of a safety-related system, the lower the probability that the system cannot
execute the required safety functions.
SIS
Safety Instrumented System: is used to protect a dangerous process and reduce the risk
of an accident. Process instruments are a constituent of a Safety Instrumented System.
This comprises the essential components of a complete safety-relevant process unit:
Sensor, fail-safe processing unit (control, evaluation device) and actuator
STP
Shielded Twisted Pair
VDE
Verband der Elektrotechnik, Elektronik und Informationstechnik (Association for
Electrical, Electronic and Information Technologies)
Repeat test
(proof test)
Repetitive test to detect hidden dangerous failures in a safety-related system.

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1.3 General functional description
The rotary measuring system is a safe and incremental position measuring system.
The measuring system has been designed so that it can be used in systems which
require the following safety functions according to EN 61800-5-2:
●Safe Direction (SDI)
●Safe Stop 1 (SS1)
●Safe Stop 2 (SS2)
●Safe Operating Stop (SOS)
●Safely Limited Speed (SLS)
●Safe Speed Range (SSR)
●Safe Speed Monitor (SSM)
●Safely-Limited Acceleration (SLA)
●Safe Acceleration Range (SAR)
●Safely-Limited Position (SLP)
●Safely-Limited Increment (SLI)
●Safe Cam (SCA)
The measuring system as a sensor is always part of a safety chain.
The following shaft designs can be used for the mechanical coupling:
●Solid shaft
●Hollow shaft
Depending on the safety functions safety-related differences arise:
●SIL3/PLe/Cat.3, in conjunction with velocity oriented safety functions
●SIL2/PLd/Cat.3, in conjunction with positioning oriented safety functions

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1.3.1 Main features
The entire system electronics has a discrete design. Neither microcontrollers nor
programmable logic elements are contained in the system electronics. There is no
interpolation or signal multiplexing. All signal lines are led separately within the
electronics.
1.3.1.1 PSEN enc sincos 4096 hs, PSEN enc sincos 4096 ss
Incremental interface with sinusoidal output signals A, /A, B, /B, Z, /Z; output level
1 Vss.
The safety-evaluated measuring system is designed for the implementation of safety-
related functions in relation to speed and direction of rotation. In the downstream fail-
safe evaluation device an ideal error detection also occurs through evaluation of the
magnitude “SIN(x)2+ COS(x)2= 1”.
The Z-, /Z-signals are not evaluated from a safety viewpoint and may not be used for
safety-oriented purposes.
1.3.1.2 PSEN enc HTL 1024 ss, PSEN enc HTL 1024 hs
Incremental interface with digital square-wave output signals A, /A, B, /B, Z, /Z; output
level in HTL logic.
The safety-evaluated measuring system is designed for the implementation of safety-
related functions in relation to speed and direction of rotation.
An internal signal monitor constantly checks the magnitude
"SIN(x)2+ COS(x)2= 1". Safety-relevant errors are indicated by switching of the signal
outputs to high impedance. The Z-, /Z-signals are not evaluated from a safety viewpoint
and may not be used for safety-oriented purposes.
1.3.2 Principle of the safety function
System safety results when:
–the scanning channel is single fault safe thanks to its own diagnostic
measures and circuit measures
–the evaluation device checks that the received incremental data meet the
expected tolerance window according to the application.
–for PSEN enc sincos the evaluation device also checks the magnitude
SIN(x)2+ COS(x)2= 1; if the result is outside the tolerance range, the
incremental data must be evaluated as unsafe. In this way the control
achieves an ideal error detection.
–when errors are detected the evaluation device introduces appropriate
safety measures defined by the system manufacturer
–the system manufacturer ensures, through correct mounting of the
measuring system, that the measuring system is always driven by the axis
to be measured and is not overloaded. A fault exclusion is required for
mounting the measuring system to the drive function.
–the system manufacturer carries out a proven test during commissioning
–the downstream fail-safe evaluation device evaluates the measuring system
differentially

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2 Basic safety information
2.1 Definition of symbols and notes
DANGER!
This warning must be heeded! It warns of a hazardous situation
that poses an immediate threat of serious injury and death and
indicates preventive measures that can be taken.
WARNING!
This warning must be heeded! It warns of a hazardous situation
that could lead to serious injury and death and indicates
preventive measures that can be taken.
CAUTION!
This refers to a hazard that can lead to a less serious or minor
injury plus material damage, and also provides information on
preventive measures that can be taken.
NOTICE!
This describes a situation in which the product or devices could
be damaged and also provides information on preventive
measures that can be taken. It also highlights areas within the
text that are of particular importance.
indicates important information or features and application tips
for the product used.
means that appropriate protective measures against ESD
according to DIN EN 61340 5-1 Supplement 1 must be applied.

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2.2 General risks when using the product
The product, hereinafter referred to as the measuring system, is manufactured
according to state-of-the-art technology and accepted safety rules. Nevertheless,
non-intended use can pose a danger to life and limb of the user or third parties,
or lead to impairment of the measuring system or other property!
Only use the measuring system in perfect technical condition, paying attention to safety
and dangers, and in compliance with the operating manual! Faults which could
threaten safety should be eliminated without delay!

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2.3 Intended use
The safety measuring system can be used for the detection of angular movement and
processing of measured data for a downstream evaluation device in systems in which
the protection goals of "Protection of speed" and "Protection of direction of
movement" must be safely achieved. The complete processing chain of the safety
function must then satisfy the requirements of the applied safety standard.
The safety measuring system may only be used in safety applications in conjunction
with an evaluation device certified according to the applied safety standard.
The system manufacturer must check that the characteristics of the measuring system
satisfy his application-specific safety requirements. The responsibility or decision
regarding the use of the measuring system lies with the system manufacturer.
Intended use also includes:
●observing all instructions in this operating manual,
●observing the nameplate and any prohibition or instruction symbols on the
measuring system,
●observing the operating instructions from the machine/system manufacturer,
●operating the measuring system within the limit values specified in the technical
data,
●ensuring that the fail-safe evaluation device fulfils all required safety functions,
●observing and using the checklist in the appendix,
●safe mounting (form closure) of the measuring system to the driving axis, also see
chapter Mounting
2.4 Non-intended use
WARNING!
Danger of death, physical injury and damage to property in case of non-
intended use of the measuring system!
➢The following areas of use are especially forbidden:
- in environments where there is an explosive atmosphere,
- for medical purposes

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2.5 Safety functions of the fail-safe evaluation device
The evaluation device, to which the measuring system is connected, must perform the
following safety checks.
With regard to "Single fault safety" and "Ideal error detection" please see IFA directive
"GS-IFA-M21".
To enable the correct measures to be taken in the case of error, the following
applies:
●Safe state –passive, only for measuring system –PSEN enc sincos
In passive safe state the measuring system does not output any valid
sinusoidal output signals to the downstream fail-safe evaluation device. The
evaluation device detects the error through evaluation of the magnitude SIN(x)2 +
COS(x)2 = 1. If the result is outside the tolerance range, the incremental data are
evaluated as unsafe. The downstream fail-safe evaluation device has an ideal
error detection.
●Safe state –active, only for measuring system –PSEN enc HTL
In active safe state the signal outputs are switched to high impedance. The
evaluation device detects the error via an implemented cable breakage detection.
2.5.1 Mandatory safety checks / measures
Measures for commissioning, changes
Error reaction
evaluation device
Check that the desired automation task is executed as
required.
STOP
Check by the evaluation device
Error reaction
evaluation device
Check of incremental data according to the present
automation task and safety function.
STOP
Two-channel monitoring of incremental outputs for cable
breakage.
For high impedance
-> STOP
Only for PSEN enc sincos
Evaluation of the condition SIN(x)2 + COS(x)2 = 1. The number
of checks / revolution corresponds to the number of
periods/revolution.
For the safety functions SDI, SS1, SS2, SOS, SSR, SSM a
magnitude monitoring with DC = 90 % is required.
For the SLS safety function a two-channel evaluation of the
frequency from (SIN/COS) with a DC of 90 % is required.
If outside tolerance
-> STOP
Only for PSEN enc HTL
A cable break detection is required for the evaluation of the
square pulse signals.
In the safe state, the output drivers are high impedance.
If a cable break is
detected
-> STOP
Only for PSEN enc HTL
Evaluation of the incremental data in differential mode and
verification with respect to antivalence, quadrature and
against phase equivalence between channels A and B
If outside tolerance
-> STOP

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2.6 Warranty and liability
All claims to warranty and liability will be rendered invalid if
●The product was used contrary to the purpose for which it is intended,
●Damage can be attributed to not having followed the guidelines in the operating
manual,
●Operating personnel are not suitably qualified,
●Any type of modification has been made (e.g. exchanging components on the
PCB boards, soldering work etc.)
2.7 Organizational measures
●The operating manual must always be kept ready-to-hand at the place of use of the
measuring system.
●In addition to the operating manual the generally valid legal and other binding
regulations on accident prevention and environmental protection must be observed
and communicated.
●The respective applicable national, local and system-specific provisions and
requirements must be observed and communicated.
●The operator is obliged to inform personnel about special operating features and
requirements.
●Prior to commencing work, personnel working with the measuring system must have
read and understood the chapter "Basic safety information".
●The type plate and any prohibition or instruction symbols applied on the measuring
system must always be maintained in a legible state.
●Do not undertake any mechanical or electrical modifications to the measuring
system, except for those expressly described in this operating manual.
●Repairs may only be undertaken by the manufacturer or a center or person
authorized by the manufacturer.
2.8 Personnel selection and qualification; basic obligations
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by competent persons.
A competent person is a qualified and knowledgeable person who, because of their
training, experience and current professional activity, has the specialist knowledge
required. To be able to inspect, assess and operate devices, systems and machines,
the person has to be informed of the state of the art and the applicable national,
European and international laws, directives and standards.
It is the company’s responsibility only to employ personnel who
●Are familiar with the basic regulations concerning health and safety / accident
prevention,
●Have read and understood the information provided in the section entitled Safety
●Have a good knowledge of the generic and specialist standards applicable to the
specific application.

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2.9 Safety information
Please note:
–Only carry out wiring work or opening and closing of electrical
connections with the system de-energized.
–Do not undertake any welding work if the measuring system is already
wired or switched on.
–Falling below or exceeding the permissible ambient temperature limit
values must be prevented through an appropriate heating/cooling
measure at the place of installation.
–The measuring system must be installed so that no direct moisture can
affect the measuring system.
–Suitable aeration/ventilation and heating/cooling measures must be
provided at the place of installation to prevent the temperature falling
below the dew point (condensation).
–Potential hazards resulting from interactions with other systems and
equipment which are or will be installed in the vicinity must be checked.
The user is responsible for taking appropriate measures.
–The power supply must be protected with a fuse suitable for the supply
lead cross-section.
–Cables used must be suitable for the temperature range.
–A defective measuring system must not be operated.
–Make sure that the installation environment is protected from
aggressive media (acids etc.)
–Avoid shocks (e.g. hammer blows) to the shaft during installation.
–Opening the measuring system is forbidden.
–When storing and operating the measuring system unused connection
plugs must either be provided with a mating plug or a protective cap.
The appropriate IP protection class must be selected to meet the
relevant requirements.
–The type plate specifies the technical characteristics of the measuring
system. If the type plate is no longer legible or if the type plate is
completely missing, the measuring system must not be operated.

Basic safety information
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The measuring system contains components and assemblies susceptible to
electrical discharge, which can be destroyed if incorrectly handled.
–Touching the measuring system connection contacts with the fingers must
be avoided, or the relevant ESD protective measures must be applied.
Disposal
–If disposal has to be undertaken after the lifespan of the device, the
applicable country-specific regulations must be observed.

Transport / Storage
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3 Transport / Storage
●Shipping information
–Do not drop the device or subject it to heavy impacts!
The device contains an optical system.
–Use only the original packaging!
Inappropriate packaging material may cause damage to the device in
transit.
●Storage
–Storage temperature: -40 to +90 °C
–Store in a dry place

Technical data
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4 Technical data
4.1 Safety
Functional safety
DIN EN 61508 part 1 to 7
Safety Integrity Level (SIL):
- 1SDI, SS1, SS2, SOS, SLP, SLI, SCA
- 2
- 1SLS, SSR, SSM, SLA, SAR
- 3
EN ISO 13849-1
Performance Level:
- 1SDI, SS1, SS2, SOS, SLP, SLI, SCA
- PLd / Cat. 3
- 1SLS, SSR, SSM, SLA, SAR
- PLe / Cat. 3
Startup time
Time between POWER-UP and safe
incremental output
PSEN enc sincos
30 ms
PSEN enc HTL
50 ms
PFH / PFHD, "High demand" operating mode
PSEN enc sincos
5,34 * 10-9 1/h
PSEN enc HTL
6.57 * 10-9 1/h
Notice
Measuring system is used only in
applications with high or continuous
demand rate
MTTFd
high
PSEN enc sincos
1558 a
PSEN enc HTL
622 a
2DCavg
medium (90 %)
Internal process safety time
Time between occurrence of an F-error and
alarm indication
Overall system
1 ms
Process safety angle
Angle between error occurrence and alarm
indication
Through channel-internal self-diagnosis
± 0.3510°, at 1024 periods;
± 0.0879°, at 4096 periods;
in relation to the measuring system shaft
T1, repeat test (proof test)
20 years
1
In accordance with EN 61800-5-2
2
The assessment occurred in accordance with Note 2 on Table 6 of EN ISO 13849-1

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4.2 Electrical characteristics
4.2.1 General
Supply voltage
10…30 V DC according to IEC 60364-4-41, SELV/PELV
Reverse polarity protection
yes
Short-circuit protection
yes, by internal 1 A safety fuse
Overvoltage protection
yes, up to 60 V DC
Power consumption without load
at 24 V DC
Analogue output signals
< 20 mA
Square-wave output signals
< 40 mA
4.2.2 Device-specific
Accuracy
Usable resolution
10 bit, 11 bit, 12 bit; depending on the device configuration
Safety-related
+ 2 bit interpolated
Functional
+ 8 bit interpolated
PSEN enc sincos
Incremental analogue output signals
Periods / revolution
4096
Incremental signals
A, /A, B, /B
Track position, electrical
90 °
Reference signals
Z, /Z, once per revolution
Output level
1 Vss ± 0.2 V at 100 , differential
Output current
20 mA
Output frequency
500 KHz
Short-circuit proof
yes
Cable specification
see Cable specification
PSEN enc HTL
Incremental square-wave output signals
Pulses / revolution
1024
Incremental signals
A, /A, B, /B
Track position, electrical
90 °
Zero pulse
Z, /Z, once per revolution
Output level HTL
Push-pull, supply voltage
Output current
50 mA, per channel
Output frequency
100 KHz
Short-circuit proof
yes
Cable specification
see Cable specification

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4.3 Ambient conditions
Vibration
DIN EN 60068-2-6
≤100 m/s2, sine 50-2000 Hz
Shock
DIN EN 60068-2-27
≤1000 m/s2, half sine 11 ms
EMC
Immunity to disturbance
EN 61000-6-2
Transient emissions
EN 61000-6-3
Working temperature
-40…+90 °C
Derating Hollow shaft, > 3000 rpm
Ta = 90 –0,0062 * (n –3000) in °C
Storage temperature
-40 °…+90 °C, dry
Relative air humidity, DIN EN 60068-3-4
98 %, non-condensing
3Protection class, DIN EN 60529
Shaft side
IP 65
Housing side
IP 67
3
valid with screwed-on mating connector and/or screwed-on cable gland

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4.4 Mechanical characteristics
4.4.1 Solid shaft
Mechanically permissible speed
12,000 rpm
Electrically permissible speed
nelectric [rpm] = (output frequency [Hz] / no. of pulses per rev.) * 60 rpm
Bearing life
≥ 3.9 * 1010 revolutions at
Speed
≤ 6000 rpm
Operating temperature
≤ 60 °C
Shaft load, flange + 10 mm
≤ 50 N axial, ≤ 100 N radial
Permissible angular acceleration
≤ 104rad/s2
Moment of inertia, typical
4.9 * 10-6 kg m2
Start-up torque
at 20 °C
3.4 Ncm
at 0 °C
3.6 Ncm
at -20 °C
7.8 Ncm
at -40 °C
20 Ncm
Weight, typical
0.3…0.5 kg
4.4.2 Hollow shaft
Mechanically permissible speed
6,000 rpm
Note
Observe Derating for permissible ambient
temperature
Electrically permissible speed
nelectric [rpm] = (output frequency [Hz] / no. of pulses per rev.) * 60 rpm
Shaft load, axial/radial
Own mass
Bearing life
≥ 3.9 * 1010 revolutions at
Speed
≤ 6000 rpm
Operating temperature
≤ 60 °C
Permissible angular acceleration
≤ 104rad/s2
Moment of inertia, typical
8.8 * 10-6 kg m2
Start-up torque
at 20 °C
3.4 Ncm
at 0 °C
3.6 Ncm
at -20 °C
3.8 Ncm
at -40 °C
16 Ncm
Runout tolerance
± 0.05 mm
Weight, typical
0.3…0.5 kg